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Split
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Technical Development Programs (TDP) are modules of technical training on HVAC theory,
system design, equipment selection and application topics. They are targeted at engineers and designers who wish to develop their knowledge in this field to effectively design, specify, sell or apply
HVAC equipment in commercial applications.
Although TDP topics have been developed as stand-alone modules, there are logical groupings of topics. The modules within each group begin at an introductory level and progress to
advanced levels. The breadth of this offering allows for customization into a complete HVAC
curriculum from a complete HVAC design course at an introductory-level or to an advancedlevel design course. Advanced-level modules assume prerequisite knowledge and do not review
basic concepts.
Spilt systems are one of the major categories of HVAC equipment, and the primary system
type used in residential air conditioning. Split systems are classified as a unitary, or packaged
unit; and, as such, have many of the benefits of packaged equipment while offering the flexibility
associated with applied products. This module will describe what split systems are, the components of the system and accessories frequently used. It will show the designer how systems are
applied, explain common installation issues, and describe how to select a system.
Printed in Syracuse, NY
CARRIER CORPORATION
Carrier Parkway
Syracuse, NY 13221, U.S.A.
Table of Contents
Introduction...................................................................................................................................... 1
Definitions and Descriptions........................................................................................................ 2
Common Use of Split Systems .................................................................................................... 2
Advantages of Split Systems ....................................................................................................... 3
Split System Basics...................................................................................................................... 3
Mix and Match Components.................................................................................................... 4
Residential and Duct Free Systems ......................................................................................... 5
Typical Split System Outdoor Unit ...................................................................................... 5
Typical Split System Indoor Unit ......................................................................................... 6
Heat Pump Systems ................................................................................................................. 7
Refrigerant Circuits ................................................................................................................. 7
Refrigerant Circuits Indoor Unit........................................................................................... 8
Codes and Standards................................................................................................................ 8
Calculating EER ...................................................................................................................... 9
Net vs. Gross Capacity............................................................................................................. 9
Example of bhp...................................................................................................................... 10
Indoor Fan Motor Heat .......................................................................................................... 10
Net Capacity .......................................................................................................................... 11
Total Power Input .................................................................................................................. 11
System EER ........................................................................................................................... 11
SEER...................................................................................................................................... 11
IPLV ...................................................................................................................................... 12
COP ....................................................................................................................................... 13
HSPF...................................................................................................................................... 13
Building Energy Codes.......................................................................................................... 14
Indoor Air Quality and Sustainable Design ........................................................................... 14
Systems and Components .............................................................................................................. 16
Rules of Thumb.......................................................................................................................... 16
Operating Limits ........................................................................................................................ 16
Outdoor Units............................................................................................................................. 17
Semi-Hermetic Compressors ................................................................................................. 17
Multiple Compressors............................................................................................................ 18
Multiple Condensing Units.................................................................................................... 18
Hot Gas Bypass...................................................................................................................... 19
Alternative Condensing Unit Solutions ................................................................................. 19
Heat Pump Outdoor Unit ........................................................................................................... 20
Indoor Units ............................................................................................................................... 21
IAQ Features.......................................................................................................................... 22
Constant Volume AHU.......................................................................................................... 23
VAV Application................................................................................................................... 23
Split System VAV Indoor Requirements................................................................................... 24
VAV Outdoor Unit .................................................................................................................... 24
VAV Control.............................................................................................................................. 25
Indoor Coil Loading Tons per Circuit................................................................................... 25
Tons per Circuit Example ...................................................................................................... 26
Cased Evaporator Coils.............................................................................................................. 27
Residential Coils ........................................................................................................................ 27
Remote Chiller Barrel ................................................................................................................ 28
Accessories ....................................................................................................................................28
Economizer ................................................................................................................................28
Heating Accessories ...................................................................................................................29
Furnaces .....................................................................................................................................29
Other Accessories ......................................................................................................................30
Controls..........................................................................................................................................30
Thermostat .................................................................................................................................30
Two-Stage Thermostat...........................................................................................................31
Electric Unloading .................................................................................................................31
Capacity Control Valve..........................................................................................................32
DDC Control..........................................................................................................................32
Safety Controls...........................................................................................................................32
Low Ambient Control ............................................................................................................33
Fan-Cycling Pressure Switch .................................................................................................34
Wind Baffles ..........................................................................................................................34
Installation......................................................................................................................................35
Electrical ....................................................................................................................................35
Power Supply .........................................................................................................................35
Protective Device ...................................................................................................................37
Disconnects ............................................................................................................................37
Installation Instructions..............................................................................................................37
Sound .........................................................................................................................................38
Elevation ....................................................................................................................................39
Suction Riser ..............................................................................................................................39
Refrigerant Piping..................................................................................................................40
Maximum Length of Refrigerant Piping................................................................................40
Long Line Applications .........................................................................................................41
System Selection............................................................................................................................41
Input ...........................................................................................................................................42
Specify Total or Sensible Cooling .........................................................................................43
Input Accessories ...................................................................................................................43
Select the System .......................................................................................................................44
Performance Data Report...........................................................................................................44
Summary ........................................................................................................................................44
Work Session 1 ..............................................................................................................................45
Notes ..............................................................................................................................................47
NotesAppendix ..............................................................................................................................48
Appendix........................................................................................................................................49
Work Session Answers ..............................................................................................................49
SPLIT SYSTEMS
Introduction
A system designer must be able to choose the system that will best fit the application. To do
this, the designer must thoroughly understand each system, its benefits, and the components that
make up the system.
A split system is a direct expansion (DX) air conditioning or heat
pump system that has an evaporator,
fan, compressor, and condenser section where one or more of the
components are separated and connected by refrigerant piping. In most
residential and commercial applications, the compressor and condenser
are combined into a single piece of
equipment called a condensing unit.
Refrigerant piping and control wiring
connects the system components and
is field-installed to meet the physical Figure 1
requirements of each individual appli- Split System Components
cation.
Split Systems
SPLIT SYSTEMS
Figure 3
ARI Definition of Packages
Figure 4
Recent Market Statistics
SPLIT SYSTEMS
A split system is
a direct expansion air conditioning
system that has an evaporator, fan,
compressor, and condenser section
where one or more of the components is
separated and connected by refrigerant
piping.
SPLIT SYSTEMS
SPLIT SYSTEMS
SPLIT SYSTEMS
Condensing units smaller than 10 tons will typically have only one compressor. Larger tonnage condensing units may have one or more compressors with 40 tons generally being the
largest single compressor unit. The
condenser in most condensing units is
air-cooled. However, water-cooled
condensing units are also available.
Figure 10
Typical Condensing Units
SPLIT SYSTEMS
Refrigerant Circuits
The number of refrigerant circuits, single or dual, may also classify split systems. This definition is most often applied to the condensing unit. 10-ton and smaller condensing units are typically
single circuit. Most single-circuit condensing units have only one compressor, however, specially
designed dual-compressor single circuit systems are available. A single circuit system may be identified by the single liquid line and single
suction line connecting the outdoor unit
to the indoor unit. Single circuit systems are the simplest systems and in
many cases are the least costly to install. Dual circuit condensing units have
two independent refrigerant circuits and
at least two compressors. Dual circuit
systems utilize two liquid lines and two
suction lines between the indoor and
outdoor units. The primary advantage
of dual circuit systems is redundancy. If
one compressor fails, the other circuit
will continue to operate and provide 50
Figure 13
percent of the nominal capacity.
Refrigerant Circuits
SPLIT SYSTEMS
SPLIT SYSTEMS
Typically, manufacturers submit data to ARI stating that a given split system has been tested
according to the applicable ARI standard and they verify the performance value in Btuh and the
Energy Efficiency Ratio (EER). This data is listed by ARI and is available to the system designers through ARI. In the case of Standard 340/360, listed systems are subject to performance
verification by ARI. To verify performance, ARI may, at any time, randomly select from a manufacturers inventory listed units or combinations. These units are sent to an independent
laboratory for performance testing. The equipment performance must match the listed values
within 5 percent. Figure 15 lists the ARI standards applicable to split systems.
Calculating EER
Since EER is used to comply with standards, it is important to understand how it is calculated.
The formula is: EER equals capacity (expressed in Btuh) divided by the total power input (expressed in Watts). EER is expressed as a pure number with the units of measure (Btuh/Watts) are
normally left off. A higher EER numCapacity (Btuh)
EER =
ber represents a higher efficiency. The
Total Power Input (Watts )
simple formula noted here is suitable
Example 25-ton condensing unit @ ARI conditions
for a stand-alone condensing unit and
listed combinations of indoor units.
Capacity (Btuh)
EER =
For example, the published capacity of
Total Power Input (Watts)
a 25-ton condensing unit operating at
290 MBtuh
95 F outdoor air and 45 F saturated
EER =
suction temperature (ARI conditions)
(22.8 + 3.1) kW
is 290 MBtuh. The power input equals
290
EER =
compressor power plus the total power
25.9
required by the condenser fan motors.
EER = 11.2
The published compressor power at the
conditions noted is 22.8 kW. The conFigure 16
denser fan motors require a total of 3.1
Calculating EER
kW.
Therefore, the EER of this 25-ton condensing unit operating at ARI conditions is:
EER= 290 MBtuh / (22.8 + 3.1) kW
EER = 290 / 25.9
EER = 11.2
SPLIT SYSTEMS
The formula for a system is: EER equals net cooling capacity (Btuh)/ total power input. Remember that the operating conditions will affect capacity; therefore, they also affect the EER. The
ARI condition for a commercial split system is defined as 80 F db and 67 F wb return air temperature, 95 F outdoor air. First, the difference in gross capacity versus net capacity must be
addressed. The capacity value published by most manufacturers is the gross capacity; that is, the
amount of heat removed by the evaporator coil. However, the indoor fan motor (IFM) adds heat
to the system which means the actual
Net Capacity (Btuh)
cooling to the space is less. Net caSystem EER =
Total Power Input
pacity during cooling mode is defined
as the gross capacity minus the indoor
Net Capacity = Gross Capacity IFM Heat
fan heat. The first step in determining
ARI Minimum External Resistance Table
the system EER is to calculate the net
Standard Ratings Minimum External Resistance
cooling capacity. To do this, you need
MBtuh
Inches of Water
to know the heat added by the IFM.
135 - 210
0.35
Typically, manufacturers data will
211 - 280
0.40
provide the brake horsepower (bhp)
281 - 350
0.45
351 - 400
0.55
requirements of the IFM operating at
401 - 500
0.65
given airflow (cfm) and resistance
501 and over
0.75
(static pressure). The ARI standard
defines the minimum external resisFigure 17
tance based on the size of the unit.
Net vs. Gross Capacity
Example of bhp
As an example, lets look at a 25ton packaged air handler operating at
10,000 cfm with 0.44 in. wg of external
static. Interpolating from the published
data, between 0.4 and 0.6 in. wg external pressure, the bhp requirement is 4.0
bhp.
AHU Size
028
Airflow
cfm
10,000
0.2
0.4
0.6
rpm
bhp
rpm
bhp
rpm
bhp
rpm
bhp
615
3.12
641
3.36
692
3.87
743
4.41
IFM Heat =
(bhp 746)
Motor Efficiency
IFM Heat =
(4.00 746)
0.83
IFM Heat =
3,595 Watts
3,595 Watts
3.414 Btuh
= 12,274 Btuh
Watts
Figure 19
Indoor Fan Motor Heat
10
SPLIT SYSTEMS
Net Capacity
Now we can determine the net capacity during the cooling mode. The manufacturers data indicates that the gross capacity of the example air handler at the conditions noted is 294 MBtuh. To
calculate net capacity:
In heating mode
Net Capacity = Gross Capacity IFM Heat
net capacity includes the
addition of fan motor heat.
(bhp 746)
Motor Efficiency
Figure 20
Total Power Input
System EER
Now you can calculate system
EER of our example 25-ton system.
System EER =
System EER =
282 MBtuh
29.5 kW
Figure 21
System EER
SEER
The Seasonal Energy Efficiency Ratio (SEER) is similar to EER in that it defines the energy
efficiency of a unit or system in the cooling mode. SEER only applies to units that operate on
single-phase power and have a capacity of 5 tons or less. SEER differs from EER in a couple of
ways. First, SEER considers the fact that the fan motor(s) and compressor cycle, therefore, the
11
SPLIT SYSTEMS
energy usage is not constant. Secondly, SEER is calculated using three operating conditions plus
a cycle test. Net capacity is determined at the ARI rating point, 80 F db, 67 F wb and 95 F outdoor air. Then ratings at two points: 80 F db, 67 F wb return air temperature, 82 F outdoor air;
and 80 F db 57 F wb return air
Applies to:
temperature, 82 F outdoor air. The
Single phase power only
later condition is used with a cyclic
Capacity less than 60 MBtuh
test to determine seasonal energy efficiency. SEER provides a means to
Calculated at three conditions and cycle test:
evaluate performance at two season 80/67 F return air, 95 F outdoor air
ally different conditions, one high
80/67 F return air, 82 F outdoor air
humidity and one low humidity. Cal 80/57 F return air, 82 F outdoor air
culating SEER involves laboratory
80/57 F cycle test, 82 F outdoor air
testing to record the power and caRequires laboratory testing and is not calculated in the field.
pacity measurements. Therefore,
SEER information is provided by the Figure 22
manufacturer and cannot be calcuCalculating Seasonal Energy Efficiency Ratio (SEER)
lated in the field.
IPLV
Integrated Part Load Value (IPLV) is used to evaluate the efficiency of a unit or system operating in the cooling mode at less than full capacity. IPLV is only applicable to equipment that has
more than one stage of capacity, for
FOR ALL 3 AND WATER-COOLED UNITS AND
example, equipment with multiple
AIR-COOLED UNITS ABOVE 60 MBH CAPACITY
compressors or a single compressor
Evaluate
equipment efficiency at less than full capacity
unit with unloading. IPLV is a
weighted average of the EER calcu- Applicable only to equipment with
PART
more than one stage of capacity
lated at each stage of capacity of the
LOAD
FACTOR
unit. A unit that has a small number of
CURVE
Weighted average of EER
steps of capacity will have a higher
at each capacity step
IPLV than one with many steps of capacity, all other factors being equal. It Equipment with greater number of capacity steps can more
closely match the load requirements of the space
is important to understand that a unit
with a higher number of steps of ca- Unless equipment is always operated at 100%
capacity, a higher IPLV is preferred
pacity will have the ability to more
closely match the cooling load of the
application and, therefore, is more efficient. Unless the unit will be operating Figure 23
at 100 percent capacity at all times, a Integrated Part Load Value (IPLV)
unit with a higher IPLV is preferred.
Note, IPLV is commonly expressed as EER (Btuh/Watt) for packaged equipment and as kW/ton for chillers. There is a fixed
relationship between kW/ton and EER (EER = 12/(kW/ton)). This relationship shows that EER
increases as kW/ton decreases, and vice versa. Therefore, a better IPLV is shown as a lower
value when the units are kW/ton, and, a better IPLV is a higher value when the units are expressed in terms of EER.
12
SPLIT SYSTEMS
COP
Coefficient of Performance (COP) is a Applies to heat pumps that operate on 3-phase power only
value used to measure a units efficiency
Measures efficiency while operating in the heating mode
while operating in the heating mode and
applies to heat pumps that operate on three- A higher COP indicates a more efficient heat pump
phase power. Since the compressor and
indoor fan motor heat provide a positive
Net Capacity (Watts )
benefit in heat pumps, their power is inCOP =
cluded in the heating calculation as a
Total Power Input (Watts )
benefit. A higher COP value represents a
Figure 24
more efficient heat pump.
COP = net capacity (Watts)/total
power input (Watts)
HSPF
Heating Seasonal Performance Factor (HSPF) is used to measure the efficiency of heat pumps
that operate on single-phase power and have a cooling capacity of less than 5.5 tons. HSPF is similar to SEER in that it represents the
seasonally adjusted heating efficiency HSPF:
of a heat pump. A higher HSPF value Applies to heat pumps that operate on single phase power
and have a cooling capacity of < 5.5 tons only
represents a higher efficiency heat
pump. Also, like the SEER, the meas Is similar to SEER in that it measures the seasonally
urement and calculation technique
adjusted efficiency of a heat pump
dictates that the testing can only be
done in a laboratory. The impacts of Accounts for defrost and required electric heat
defrost and supplemental heaters are
A higher HSPF is a more efficient heat pump
factored into these calculations as well.
Figure 25
Heating Seasonal Performance Factor (HSPF)
13
SPLIT SYSTEMS
Performance
requirements
safety of the building occupants. How< 65,000 Btuh
10.0 SEER 1
ever, after the energy crunch of the
65,000 < 135,000 Btuh
10.3 EER
1970s, building performance standards
135,000 < 240,000 Btuh
9.7 EER
started to become a provision of build 240,000 < 760,000 Btuh
9.5 EER / 9.7 IPLV
ing codes. This activity has continued
760,000 Btuh
9.2 EER / 9.4 IPLV
and today, energy requirements are a
Control requirements
part of nearly every building code. One
Motor hp limits
important point about building codes is
Economizer requirements
that they establish minimum levels.
Heat pump requirements
Buildings may be built to levels that
are more stringent but not less. Several Figure 26
ASHRAE standards have become inEnergy codes establish air-cooled split system minimum performance
corporated into code requirements.
requirements.
ASHRAE 90.1,Energy Standard for
Buildings except Low-Rise Residential Buildings, has become the benchmark for energy codes. At
the very basic level, you may consider ASHRAE Standard 90.1 as defining minimum energy efficiency standards for a variety of devices, including air conditioning equipment. As this standard
applies to split systems, it defines the minimum EER, IPLV, and COP of systems, or, in some cases
individual units, such as large condensing units. It also has a number of other provisions that affect the
design of split systems. These provisions include requirements on the control system, limits on the
indoor fan motor horsepower, requirements on the use of an economizer and requirements on heat
pumps. Additional information on these requirements can be found in Sections 6.2 and 6.3 of the
Standard.
A key factor when comparing efficiency values of split systems is to ensure that you are
comparing apples to apples. For example, when comparing two brands, do the values reflect the
total of the indoor and outdoor units? If both values represent the system efficiency, are the airflow and static pressure values for the indoor unit the same? If not, the comparison is not valid.
IAQ ASHRAE 62
Limits maximum humidity to less than 65%
Indoor unit condensate control
Indoor unit ventilation capability
Figure 27
IAQ and Sustainable Design
14
SPLIT SYSTEMS
This standard has tables that set minimum ventilation airflows based on the type of building,
the usage of the space, the number of people, and the space area. It also contains a number of provisions that influence the use of split systems. One of these requirements is to control the chance
of mold growth. Humidity in the space must be kept below 65 percent. ASHRAE Standard 62
addresses moisture by limiting the allowable relative humidity in an occupied space to 65 percent
or less at either of the following two design conditions:
Peak outdoor dew point design conditions and peak indoor design latent load, or
Lowest space sensible heat ratio expected to occur and the concurrent (simultaneous)
outdoor conditions.
ASHRAE Standard 62 also notes that the load on a space may be significantly different at
outdoor dew point design conditions than at outdoor dry bulb design conditions. It is important to
design the system to handle the worst-case scenario, which may be the dew point design condition. The Standard also requires the design minimum outdoor air intake airflow to be greater than
the design maximum exhaust airflow. In other words, the total building must be pressurized, understanding that certain spaces within the building may be at a negative pressure condition.
Ventilation requirements in split system applications may be handled in a variety of ways.
The ventilation may be addressed directly in the split system by equipping the indoor section with
a mixing box or economizer section. The ventilation needs may also be addressed by dedicated
outdoor air system that is independent of the split system.
Split systems can offer a distinct advantage in dealing with these requirements. When spaces
have high latent requirements because of the activity in the space or large amounts of humid outdoor air, humidity control can be a challenge. As indicated before, split systems allow a variety of
system matches and the use of DX allows lower coil temperatures, which can result in much better humidity control.
Provisions must also be made for ventilation air ducted to each unit, which can impact the location of the indoor air handler. In addition, requirements for control of condensate within the air
handler dictate the use of condensate pans with no standing water, double-wall construction, surfaces downstream of the coil protected from condensate damage and other IAQ protection
measures. These measures may influence the air handler selected or the options required.
While energy efficiency and IAQ have dealt with setting a minimum performance standard
for units, there is interest today in programs that promote achieving a superior level of energy
performance and IAQ. These efforts are commonly called sustainable design, green buildings, or
by the most common certifier of these buildings, LEED (Leadership in Energy and Environmental Design). These programs are aimed at driving building design to achieve the maximum
economical performance and minimal environmental impact. The LEED program requires
meeting all the requirements of the ASHRAE 90.1 Energy Standard and the ASHRAE 62 requirements of the Ventilation Standard. It then uses these standards as a benchmark to measure
how much performance has been improved. Split systems, with the ability to closely match the
load requirements and offer superior part load control, are worthy of consideration for projects
seeking high levels of indoor air quality and LEED certification.
15
SPLIT SYSTEMS
Operating Limits
There are a number of parameters that define the proper operating envelope for a split system.
These include:
16
SPLIT SYSTEMS
Although a heat pump can safely operate at very low temperatures, it should be understood
that a heat pump does not operate efficiently at low temperatures. Therefore, heat pump systems
may employ supplemental heating systems, most commonly electric heaters in the indoor units.
In some applications, building codes set the need for heaters and the size of the heaters.
It is incumbent upon the designer to make sure that the equipment selected will operate
within these limitations throughout the operating envelope of the application.
Outdoor Units
Lets discuss some of the variables found in outdoor units, or more generically, condensing
units. Obviously, one variable is size, or capacity. As described earlier, residential condensing units
typically have a nominal capacity
range of 1 tons to 5 tons. Commercial condensing units range in size
from a nominal 6 tons to 120 tons and
greater. Another variable is the type of
compressor. Typically, condensing
units with a nominal capacity of 10
tons or less use hermetic type compressors, with scroll compressors being
the most common today. This choice
provides a reasonably priced compressor that meets the relatively simple
need of a small split system.
Figure 29
Outdoor Unit
Semi-Hermetic Compressors
10-ton and larger condensing units may be equipped with reciprocating semi-hermetic compressors. The semi-hermetic compressor offers the flexibility of a repairable compressor vs.
replacement being the only option with
a failed hermetic compressor. More
importantly,
reciprocating
semihermetic compressors offer the capability of capacity control through
cylinder unloading. This provides a
means for a relatively large singlecompressor condensing unit to adjust
its capacity to meet the load requirements of the application. For example,
a 40-ton semi-hermetic compressor
may have 3 stages of capacity, 100
percent, 67 percent, and 33 percent. In
other words, this 40-ton compressor
may operate at 40 tons, 27 tons, or 13 Figure 30
tons, depending on the needs of the Semi-Hermetic Compressor
application.
17
SPLIT SYSTEMS
Multiple Compressors
Condensing units may also be equipped with more than one compressor. Typically, multiple
compressor condensing units have a nominal capacity of 10 tons or larger. Many multiple compressor condensing units are dual circuit units. The use of multiple
compressors provides another
means of capacity control, i.e., by
turning compressors on and off,
the total capacity of the condensing unit may be changed. It is
possible to have multiple compressors manifolded together on a
single circuit, however this requires special consideration by
the equipment designer in the
area of compressor oil manage- Figure 31
ment.
Multiple Compressors
18
SPLIT SYSTEMS
19
SPLIT SYSTEMS
a triple split in which the separate compressor and fan coil are indoors and the air-cooled
condenser is outdoors using propeller fans or indoors using centrifugal fans.
Figure 35
Heat Pump in Heating Mode
20
SPLIT SYSTEMS
The design of the outdoor coil in a heat pump also receives special attention. In order for the coil
to operate effectively as both a condenser and an evaporator, the coil must be designed and tested
to work in conjunction with a particular indoor unit (coil). For this reason, heat pumps are provided as a system only, an outdoor unit matched with an indoor unit. It is not possible to mix and
match indoor and outdoor units in a heat pump application unless the combination has been
tested.
Figure 36
Heat Pump in Cooling Mode
Indoor Units
In most commercial applications, the indoor unit will be an air-handling unit (AHU), also
known as an air handler. The AHU may be a simple packaged air handler. Packaged AHUs are
typically available in capacities from 6
to 30-ton with the term packaged
indicating that the product offering is
available in a limited number of predefined sizes. The advantage of the
packaged air handler is that the
TXV(s) and nozzle(s) are factory installed. The other end of the spectrum
for commercial AHUs is the applied
air handler or central station air handler. The term applied is an
appropriate description because air
handlers of this type are designed and
constructed in modules, based on the
needs of the application. For example, Figure 37
the designer chooses the fan section,
Indoor Unit Air Handler
the coil, the filter section, etc.
Commercial HVAC Equipment
21
SPLIT SYSTEMS
IAQ Features
Indoor Air Quality (IAQ) features are an important consideration when selecting an AHU. The
type of construction is a very basic choice. An AHU with double-wall construction sandwiches the
insulation between the outer casing and an interior metal liner. This design prevents exposure of the
insulation to the moving airstream, thereby eliminating any possibility that insulation particles may
be carried into the space. Double-wall construction is common on built-up style AHUs, but typically is not available on packaged AHUs. Packaged air handlers typically use a dual-density, coated
insulation, which is designed for exposure to the moving airstream, yet will not shed particles at
velocities encountered inside the AHU. This type of
insulation may also be
treated with an antimicrobial coating to inhibit
the growth of bio-aerosols
inside the AHU. Foil-faced
insulation is also common
in packaged air handlers.
The double-wall system or
the insulations described,
all offer an AHU interior
that may be cleaned. Ultraviolet UV-c lights mounted
inside the AHU may also be
utilized to limit the growth
of bio-aerosols on the coil Figure 38
or in the drain pan.
IAQ Features
22
SPLIT SYSTEMS
VAV Application
As the name implies, the volume of air moving through the VAV system is variable. The air
handler fan must be capable of changing its airflow to respond to load changes in the space. This
may be accomplished in a number of
ways. The speed of the fan in the AHU
may be variable, perhaps controlled by
a variable frequency drive (VFD). The
fan may be equipped with inlet guide
vanes that mechanically change the
inlet flow conditions to the fan, thereby
varying the airflow. The air volume
may also be controlled at the end of the
ductwork, at the terminal devices.
VAV terminals effectively throttle the
airflow into the space, thereby varying
the airflow in the system.
VFDs
Figure 40
Variable Volume Units
23
SPLIT SYSTEMS
24
SPLIT SYSTEMS
VAV Control
VAV split systems must be equipped with a control device or controller. This VAV controller
must be capable of starting and stopping the compressors, staging the steps of capacity of both the
indoor and outdoor unit, and controlling the fan. A typical VAV controller
is a discharge air controller. The controller utilizes a sensor in the
ductwork, downstream of the AHU.
Based on the sensed supply air temperature and the offset from set point,
the controller will vary the stages of
capacity to maintain a reasonably constant discharge air temperature. The
VAV controller may be as simple as a
self-contained device or it may be part
of building automation system.
Figure 42
VAV Controller
25
SPLIT SYSTEMS
tubes, the minimum tons per circuit is 0.6 tons per circuit. The refrigerant velocity will be lowest
when the compressor is unloaded. Whenever you wish to add an unloader to a system, you must
consider the refrigerant velocity at the minimum capacity step, when the compressor is fully
unloaded.
15
30
Is the ton per circuit value high enough for adequate oil return when the compressor is
fully unloaded?
It will only be possible to add additional unloading if you can satisfy both areas of concern.
26
SPLIT SYSTEMS
Figure 45
Cased Evaporator Coils
Residential Coils
Residential
evaporator
coils are similar to the cased
evaporator coils described
above, yet in smaller tonnage
ranges. The coils are traditionally installed on the
discharge side of a furnace.
The coils are available in a
number of configurations,
A, N, slab, and in cased
or uncased designs. The A,
N, and slab refer to the
shape the evaporator coil re- Figure 46
sembles.
27
SPLIT SYSTEMS
Accessories
Economizer
An important consideration in any split system is the introduction of outdoor air for ventilation
purposes. One way to accomplish this is by using an economizer that also provides the benefit of
free cooling when ambient conditions are appropriate. Historically,
economizer control types included dry
bulb control, enthalpy control, and differential enthalpy control. Today, CO2
sensing is also a popular control
method. The use of a CO2 sensorcontrolled economizer provides an effective method of demand controlled
ventilation (DCV) for split systems.
As noted earlier, energy codes
like ASHRAE 90.1 may require the
use of an economizer and may dictate
Figure 48
which type of control is to be used.
Economizer
28
SPLIT SYSTEMS
Heating Accessories
The indoor units discussed previously focused on cooling only. Of course, many split systems
also incorporate heating components. Heating may be accomplished in a variety of ways. Heating
accessories for packaged air handlers include: electric, hot water, and steam heating options. These
accessories are typically installed on
the leaving airside of the packaged air
handler. If the system is a heat pump,
the coil in the indoor unit will provide
heating when the system is operating
in the heating mode. This type of heat
may be referred to as mechanical
heating. Heat pump indoor units may
also be equipped with accessory heating devices when the application
requires more heat than the heat pump
system can provide and to provide
heating during defrost conditions.
Figure 49
Heating Accessories
Furnaces
Heating may be supplied by a furnace. This furnace may be of the
typical design with a cooling coil on
the leaving side of the furnace. The
furnace may also be a duct type furnace (not shown) placed downstream
of the air handler. Furnaces can also be
used in pre-selected pairs as shown,
called twinned furnaces.
Figure 50
Furnace Applications
29
SPLIT SYSTEMS
Other Accessories
A variety of other accessories may be available to complete the split system installation. These
include:
Return air grille, also used on free return to prevent larger debris from entering the unit.
Controls
Thermostat
From a control perspective, the typical split system is very simple. For this reason, the control is
quite frequently a simple thermostat. The devices to be controlled include: indoor fan, outdoor fan,
compressor, and liquid line solenoid (if
equipped). On a very simple, small
tonnage system, when the thermostat
calls for cooling, the indoor fan is
started, the liquid line solenoid opens,
and the outdoor fan and compressor
are started. When the thermostat is satisfied, the liquid line solenoid is
closed, the compressor and condenser
fan are cycled off, and the indoor fan
stops. This type of control is known as
solenoid drop control.
Figure 52
Control Thermostat
30
SPLIT SYSTEMS
Two-Stage Thermostat
Dual circuit systems may be controlled similarly with a two-stage
thermostat. In these applications, the
first stage cooling (Y1) initiates the first
circuit of the condensing unit. If the first
circuit cannot satisfy the load demand
on the space, the second stage cooling
(Y2) function of the thermostat will
initiate the second stage of the condensing unit.
Figure 53
Two-Stage Thermostat
Electric Unloading
A two-stage thermostat may also
be used to control a single reciprocating compressor equipped with an
electric unloader. Y1 will start the
cooling sequence as described previously and unload the compressor. In
this way, the compressor will be operating at less than full capacity when the
load is light. If the load cannot be satisfied with the compressor operating
unloaded, Y2 will initiate and cause
the compressor to load, thereby providing full coil capacity.
Figure 54
Electric Unloading
31
SPLIT SYSTEMS
DDC Control
Safety Controls
On a typical split system, the condensing unit is equipped with several
safety controls. These may include:
32
SPLIT SYSTEMS
Oil pressure switch, on some units, that protects against a lack of lubrication.
Compressor over-temperature switch, used on some units and internal to the compressor, to
protect against compressor overheating.
Circuit breakers, used on some units, others have internal protection, which protect against
electrical motor overload.
The indoor unit is typically equipped with indoor fan motor protection (internal protector or
circuit breaker). Additionally, a common field-supplied safety is a proof-of-airflow switch. The
proof-of-airflow switch is interlocked with the outdoor unit controls to prevent compressor operation if there is no airflow, in the event of indoor fan motor or belt failure. The primary control
circuit is usually located in the condensing unit control box and the indoor and outdoor circuits
need to be interlocked with field-installed control wiring.
33
SPLIT SYSTEMS
Wind Baffles
An additional element of the low ambient control system is the wind baffle. If the condenser
coil is exposed to sustained winds, controlling the number of operating fans and/or, fan speed, may
not maintain SCT at a reasonable level.
The force of the wind alone may provide more air movement across the coil
than is desired. In these applications, it
is necessary to install wind baffles, at
least on the windward side of the unit.
Condensing units that employ horizontally-mounted coils do not require
wind baffles.
Figure 60
Wind Baffles
34
SPLIT SYSTEMS
Installation
Designers should understand several issues related to installation in order to do a better job in
system design. Understanding the requirements for electrical service, location, refrigerant piping,
and control interfacing will result in more satisfactory split system designs.
Electrical
A split system has four electrical service requirements that need to be meet. First, the size of the
wiring that needs to be run to the indoor and outdoor sections must be determined. Then the size of
the fuse or circuit breaker that will protect each of the two sections from electrical overload needs to
be determined. Third, the disconnect requirements for both the indoor and outdoor sections need to
be specified. Finally, the requirements that interlock the two sections must be determined.
Power Supply
Another important part of the system designers task is to define the power supply needed for
the split system. Typically, this will involve at least two power circuits, one for the indoor unit, and
one for the outdoor unit. If the
indoor unit is equipped with
Minimum Circuit Ampacity (MCA)
electric heat and requires only
determines required wire size
one power supply, this is called
a single point connection. If
MCA = (1.25 Current of largest motor)
+ Sum of all other loads
the electric heat is a duct heater
or an add-on to the air handler,
MCA of a condensing unit = (1.25 RLA of compressor)
it may require separate power
+ (FLA of OFM motors
supplies for the air handler and
+ Control amps)
the electric heater. The key
terms to understand in defining MCA of indoor unit with electric heat = (1.25 FLA of largest motor)
the power supply requirements
+ (1.25 FLA of electric heater)
+ Sum of all other loads
are Minimum Circuit Ampacity
(MCA) and Maximum OverFigure 61
current Protection (MOCP).
Power Supply MCA
35
SPLIT SYSTEMS
MCA
The value of the MCA determines the wire size required for the circuit. MCA is calculated:
MCA = (1.25 current of the largest motor) + sum of all other loads
The amperage drawn by a compressor depends on the operating point; the industry has agreed
to determine this current draw at a selected set of operating conditions indicative of normal
maximum current draw. This value is referred to as run load amps (RLA). Other motor amperage
is listed based on the motor operating at fully-loaded conditions without going into the service
factor, referred to as the full load amps (FLA).
Therefore, the MCA of a condensing unit would be:
MCA = (1.25 RLA of the compressor) + (FLA of the OFM motors) + Control Amps
The MCA of an indoor unit is calculated similarly unless it is equipped with electric heat. If
equipped with electric heat, the MCA is:
MCA = (1.25 FLA of the largest motor) + (1.25 FLA of the electric heater) + sum of all
other loads
MOCP
The MOCP value defines the maximum overcurrent protective device. The key word is
maximum. If the MOCP for a condensing unit is 60 amps, this means the largest overprotection
device (fuse or circuit breaker) allowed by UL or the NEC (National Electric Code) is 60 amps. If
a 50-amp device is used, that is not a problem from the perspective of UL or NEC. The risk in
using a smaller fuse or circuit breaker is that the unit could trip the protective device on start-up
or in times of high current draw, for example, in high ambient conditions. The designer must consider the benefit of a smaller protective device (less cost) compared to the potential for nuisance
tripping of the protective device. To calculate MOCP:
MOCP = (2.25 current of the
largest motor) + sum of all the other
loads
MOCP
ROCP
There is an alternate method of calculating overcurrent protection known as recommended
overcurrent protection (ROCP). To calculate ROCP:
ROCP = (1.5 current of the largest motor) + sum of all the other loads
UL1995 states that a value smaller than the MOCP, i.e., ROCP, may be published, if the unit
is tested at the lower value and does not trip the over current protection device. The key point is
that the unit must be tested at the lower value to confirm that it will function without nuisance
trips of the overcurrent device.
36
SPLIT SYSTEMS
Protective Device
The type of protective devices used in the HVAC industry may be fuses or circuit breakers, depending on the application and locale. If circuit breakers are used, they must be a type specifically
designed for the HVAC industry,
known as HACR breakers (heating and
air conditioning rated). Generally
speaking, HACR breakers will be used
whenever acceptable by code and
when available in the size required.
Fuses will be used if required by code
or if the MOCP value is greater than
the largest HACR breaker available.
Be sure to check the manufacturers
installation information since some
units will be rated for use with fuses
only.
Figure 63
Protective Devices
Disconnects
For safety reasons, electrical codes
such as the NEC require that a disconnecting device be located within line of
sight of the unit. This disconnect may be
installed in the field by an electrician or
it may in some cases be provided as a
factory-installed option. Disconnects
may be fused or non-fused. If a nonfused disconnect is used to meet the
disconnecting device requirement of
the NEC, the circuit must still be protected by fuses or HACR breakers.
These protective devices would then be Figure 64
located between the non-fused disconDisconnects
nect and the electrical power service to
the building.
Installation Instructions
For specific information regarding installation, it is imperative to consult the manufacturers installation instructions. Different units and different manufacturers for the same tonnage may have
very different requirements for clearances, electrical service and refrigerant piping requirements.
However, there are a number of general considerations that apply to most installations.
37
SPLIT SYSTEMS
Installation cautions:
Check the manufacturers installation
instructions, different units and
manufactures will have different
requirements for refrigerant piping,
location and electrical requirements.
Locate the indoor and outdoor units
as close together as possible, Check
for both refrigerant lift and run
restrictions
Provide adequate service clearance
and operational clearance.
Unit location must also take into consideration condenser coil airflow (outdoor unit) and
maintenance accessibility. Always refer to the manufacturers recommended clearances when
deciding where and how to locate the equipment. For the outdoor unit, be sure to consider the
potential for vegetation growth blocking the coil in the future. Service pads are required for units
mounted on the ground. It is sometimes desirable to hide the condensing unit for sound or aesthetic reasons. When this is done be sure that the barrier allows for adequate airflow and that it
does not cause recirculation of hot condenser air.
Sound
The sound produced by air-conditioning equipment is becoming increasingly important as designers, owners, and occupants seek quieter and quieter environments. It must be recognized that
split system components will produce sound, and steps must be taken to insure that the sound produced is not objectionable. The sound level produced by the equipment is typically identified in the
unit product data. Manufacturers may
also provide sound reduction accessories for the equipment to reduce the
sound produced. It is equally important that designers consider the impact
of sound when locating equipment.
For example, it would not be wise to
locate a large condensing unit on the
roof of an office building if the space
directly below is the company presidents office. It would not be wise to
locate a packaged air handler in a
closet with louvered return air doors at
the back of a classroom. When in
doubt regarding sound issues, utilize
the services of a skilled acoustical Figure 65
consulting engineer.
Typical manufacturers sound ratings.
38
SPLIT SYSTEMS
Some units have options available that can be used to assist in controlling the sound levels.
These should be used whenever the job is acoustically sensitive.
One often-overlooked sound issue with split systems is the refrigerant piping. It is good design practice to allow for some movement in the piping, and use piping supports to isolate the
units and prevent the piping from transmitting vibration and noise.
Elevation
The indoor and outdoor sections
may be located at the same elevation or
they may be located on different elevations. If the indoor unit is located
above the outdoor unit, the outdoor
unit must lift the liquid refrigerant up
to the indoor unit. In this case, the designer must confirm that the vertical
distance between the indoor and outdoor unit does not exceed the liquid lift
capability of a condensing unit. If the
separation is too great, one or both of
the components must be relocated. The
lift impacts the pressure drop in the
liquid line. Excess pressure drop can Figure 66
result in the liquid flashing to vapor in Elevation
the line and result in hunting problems
with the TXV.
Suction Riser
If the outdoor unit is located above the indoor unit, consideration must be given to the vertical
section of the suction piping known as the suction riser. In order to ensure proper compressor oil
management, the velocity of the refrigerant must be high
enough to entrain compressor oil with suction vapor in the
Double suction risers
suction line. The manufacturers data may also define
Are avoided by using single suction
limitations on the maximum length of suction risers where
risers that are sized for oil
applicable. In some cases, it may be necessary to use two
entrainment at minimum load. If the
refrigerant lines in the suction line to assure adequate vesize of the single suction riser
locity for oil return. This arrangement is referred to as a
results in excessive pressure drop,
then a double suction riser may be
double suction riser.
necessary.
39
SPLIT SYSTEMS
Refrigerant Piping
Proper sizing and installation of refrigerant piping is imperative for proper operation and long
component life in a split system. Information regarding refrigerant piping practices and methods
may be found in TDP-501, Refrigerant Piping.
Caution: DO NOT bury refrigerant piping underground! Buried
refrigerant lines can result in refrigerant condensing taking place in the
lines and liquid refrigerant slugging
back to the compressor.
Remember to select the proper
size refrigerant lines (tubing) for split
system applications. There are a number of sources of this information;
always use the manufacturers data
when it is provided. If this data is not
available from the manufacturer, then
alternate sources such as the Carrier
Refrigerant Piping Software and System Design Manual may be used.
Refrigerant lines should always be Figure 67
sized for no more than a 2 F line loss. Refrigerant Piping Sizes (6-10 Ton, R-22)
Note:
Always consult manufacturers
recommendation for the length of
refrigerant lines. As a general
recommendation line lengths over 75
ft or so, are considered long line. Lift
over 25 ft should be checked for
capability with the system being used.
Heat pumps are limited to 100 ft of line
length.
40
SPLIT SYSTEMS
System Selection
Selection of split
system units can be
more complicated than
the selection of packaged rooftop equipment for two reasons.
First, it is possible to
match a condensing
unit to several different
combinations of evaporators, and second, a
considerable distance
may separate the evaporator and condensing
unit. Both of these can Figure 68
influence the selection. Balance Diagram
In the past, it was necessary to
make a selection by graphically plotting the performance of a condensing
unit against the performance of an
evaporator using a balance diagram.
Since electronic selection programs
have become available, computers
can easily perform the balance.
Manufacturers now provide split
system selection software tools that
evaluate both the indoor and outdoor
unit as a system. As an example, the
Carrier selection program is used in
Figure 69
the next few sections to explain the
Sample Input of Carriers E20 Input Screen
procedure and the required inputs.
The programs result in outputs that provide the designer with all the information normally required to complete the schedule for the design drawings.
41
SPLIT SYSTEMS
The first data input screen is primarily for project management, with the exception of the altitude input. Inputting an altitude above sea level, will automatically be compensated for air density
at the altitude specified. A Tag is just a name for the unit, for example SSU-1 Office area.
Input
Next, select the type of equipment,
DX Cooling, DX Heat Pump, or
Chilled Water. If one of the DX
choices is selected, the program will
select a system using an indoor and
outdoor unit. If Chilled Water is selected, the program will select a chilled
water indoor unit only. Electrical service
is
the
next
important
consideration. Select the electric service for the indoor and outdoor units.
The values do not have to be the same. Figure 70
The only other data that is required to Input Screen
make a selection is indoor unit airflow.
42
SPLIT SYSTEMS
Figure 73
Specify Cooling Needs
Input Accessories
If the indoor unit will be equipped
with accessories that will affect the
units performance, you should click
on the accessory tab. Select the appropriate accessories and then recalculate.
Figure 74
Add Accessories
43
SPLIT SYSTEMS
Figure 75
Performance with Accessories
Figure 76
Performance Report
Summary
The objective of this module has been to familiarize the participants with split system equipment, the nature of the business,
and the technical aspects of selection and application of split systems. Specific attention has been given to the flexibility of the
system, issues which are specific to split systems and the tools
available to the designer.
Split systems
provide the designer
increased flexibility with the
benefits of packaged
equipment.
44
SPLIT SYSTEMS
Work Session 1
Multiple-choice questions may have more than one correct answer; identify all correct selections.
1. A typical commercial split system includes _____.
a) an indoor unit only
b) a compressor, an indoor fan, an evapora- d) a compressor, an indoor fan, an evapotor and condenser as one or more
rator and condenser as a package
sections
2. True or False? All commercial split systems are at least dual circuit. __________
3. True or False? Net capacity will always be greater than gross capacity. __________
4. SEER applies to _____
a. units which are cooling and heat
5. The standard ARI rating condition used to calculate EER for commercial splits is _____
a. 80 F db/57 F wb indoor , 82 F outc. 80 F db/67 F wb indoor, 95 F outdoor
door
b. 70 F db/57 F wb indoor, 47 F outdoor
6. True or False? Semi-hermetic compressors may be equipped with unloaders for capacity
control. __________
7. True or False? Heat pump systems can always match an indoor unit one size above the
nominal capacity of the outdoor unit. __________
8. The condensing unit used in a VAV application will differ from a condensing unit used in a
CV application in which of the following ways? _____
a. They are the same only the indoor section is different.
45
SPLIT SYSTEMS
9. Calculate the MOCP and MCA for a condensing unit that has one compressor rated at 75
amps, one indoor fan rated 21 amps, and two outdoor fans rated at 6 amps each.
_________________________________________________________________________
10. Find the system EER for a unit with a gross capacity of 137,000 Btuh, two OFM motors at
1500 Watts, and a 5 hp indoor fan motor operating at 4.1 bhp. The compressor draws 6 kW.
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
11. Refrigerant lines with a length greater than 75 feet require _____.
c. a receiver
12. A condensing unit can be unloaded from 10 tons to 4 tons, the indoor coil has 20 circuits of
3/8 in. tube. Is this an acceptable combination? Why? _____________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
13. Split systems are a good selection for applications_____.
a. requiring high latent capacity.
c. Condensate trap
d. Unit mounted disconnect switch
b. Enthalpy-controlled economizer
15. Residential systems differ from commercial systems in the following ways. _____
a. Because they do not have any options
46
SPLIT SYSTEMS
Notes
47
SPLIT SYSTEMS
Notes
48
SPLIT SYSTEMS
Appendix
Work Session Answers
1. c. split systems are two or more sections
2. False units may be single or dual circuit
3. False gross capacity is larger on cooling equipment
4. a. SEER applies to both
c.
5. c.
6. True, this is the way it is done
7. False heat pumps are only nominal capacity and tested combinations
8. c.
d.
9. MOCP = 1.25 Largest Motor + Sum of other motors
MOCP = 1.25 75 + 6 2 = 105.75 amps
MCA = 2.25 largest motor + sum of other motors
MCA = 2.25 75 + 6 2 = 180.75
Closest size is a 175-amp fuse
10. First determine the net capacity
Net capacity = Gross capacity fan heat
IFM Watts = (BHP*746)/motor efficiency = (4.1*746)/0.83 = 3685 Watts
IFM Heat = Watts * 3.414 Watts/Btu = 3685 * 3.414 = 12,580 Btuh
Net Capacity = 137,000 12,580 = 124,420 Btuh
Now determine system power
Total Power = IFM + OFM + Compressor
Total Power = 3685 + 2* 1500 + 6000 = 12685 Watts
Then system EER is EER = Net capacity/Watts = 124,420 Btuh/12685 Watts = 9.8 EER
11. b.
12. Minimum tons /circuit for 3/8-in. tube is 0.4 tons per circuit.
Tons/circuit for this example = 4 tons/20 circuits = 0.2 tons per circuit; TOO LOW!
13. a.
b.
d.
14. d.
15. c.
49
SPLIT SYSTEMS
Notes
50
Prerequisites:
This module assumes the participant has an understanding of industry terminology, basic concepts of the air conditioning, and the mechanical refrigeration process. The following TDPs are
good reference for this material:
Form No.
Color
Book
Instructor
Presentation
Title
TDP-102
TDP-103
TDP-105
TDP-401
TDP-404
796-026
796-027
796-029
796-037
796-040
797-026
797-027
797-029
797-037
797-040
ABCs of Comfort
Concepts of Air Conditioning
Comfort Design Steps
Principles of Mechanical Refrigeration
Compressor Types
Learning Objectives:
At the conclusion of this module, participants will be able to:
Supplemental Material:
Additional information on subject covered in this module may be found in:
Form No.
Color
Book
Instructor
Presentation
TDP-501
TDP-403
TDP-701
TDP-702
796-042
796-039
796-066
796-067
797-042
797-039
797-066
797-067
Title
Refrigerant Piping
Expansion Devices and Refrigeration Specialties
System Features and Selection Criteria
Comfort Control Principles
Instructor Information
Each TDP topic is supported with a number of different items to meet the specific needs of the
user. Instructor materials consist of a CD-ROM disk that includes a PowerPoint presentation
with convenient links to all required support materials required for the topic. This always includes:
slides, presenter notes, text file including work sessions and work session solutions, quiz and
quiz answers. Depending upon the topic, the instructor CD may also include sound, video,
spreadsheets, forms, or other material required to present a complete class. Self-study or student
material consists of a text including work sessions and work session answers, and may also
include forms, worksheets, calculators, etc.
Carrier Corporation
Technical Training
800 644-5544
www.training.carrier.com